Bale wrap mechanism

ABSTRACT

A bale wrap mechanism including a frame including a wrap chute formed from one or more perimeter walls, where the wrap chute includes a wrap axis extending longitudinally therethrough, and where the one or more perimeter walls at least partially define a passageway, a first rail fixedly coupled to the frame, a first shuttle movable along the length of the first rail, where the first shuttle includes a second rail that is transverse to the first rail, a second shuttle movable along the length of the second rail, wherein the second shuttle includes a mounting point, and a shaft coupled to the mounting point, where the shaft is configured to rotatably support the roll of wrap material thereon, and where the shaft is configured to travel along a wrap path during a wrapping process, where the wrap path surrounds the passageway, and where the wrap path is non-circular in shape.

CROSS-REFERENCED TO RELATED APPLICATION

This patent application claims priority to U.S. Provisional PatentApplication No. 62/466,869, filed Mar. 3, 2017, which is herebyincorporated by reference.

FIELD

The present disclosure relates to an agricultural baler having a wrapmechanism.

BACKGROUND

During the baling process, crop material is collected from a supportsurface or field and compressed into an extrusion of compressed cropmaterial and divided into discrete bales. Once divided, the individualbales may be wrapped by a wrapping mechanism before being dischargedfrom the baler. The wrapping helps maintain the integrity of the balesafter they have left the confines of the baler itself.

SUMMARY

In one implementation, a bale wrap mechanism for wrapping a bale withwrap material, the bale wrap mechanism including a frame including awrap chute formed from one or more perimeter walls, where the wrap chuteincludes a wrap axis extending longitudinally therethrough, wherein theone or more perimeter walls at least partially define a passagewaythrough which a bale may be passed, and where the perimeter walls formone or more notches through which the wrap material may contact thebale, a wrap arm having a mounting point movable with respect to theframe, a roll coupled to the mounting point of the wrap arm, the rollhaving at least a portion of the wrap material wrapped thereon, and abrake assembly configured to adjust the tension of the wrap material,where the mounting point is configured to travel along a wrap pathduring a wrap process, and where the wrap path includes one or moresegments each separated from one another by a notch, and where the brakeassembly is configured to adjust the tension of the wrap material ineach segment independently.

In another implementation, a bale wrap mechanism for use with a roll ofwrap material, the bale wrap mechanism including a frame including awrap chute formed from one or more perimeter walls, where the wrap chuteincludes a wrap axis extending longitudinally therethrough, and wherethe one or more perimeter walls at least partially define a passageway,a first rail fixedly coupled to the frame, a first shuttle movable alongthe length of the first rail, where the first shuttle includes a secondrail that is transverse to the first rail, a second shuttle movablealong the length of the second rail, wherein the second shuttle includesa mounting point, and a shaft coupled to the mounting point, where theshaft is configured to rotatably support the roll of wrap materialthereon, and where the shaft is configured to travel along a wrap pathduring a wrapping process, where the wrap path surrounds the passageway,and wherein the wrap path is non-circular in shape.

Other aspects of the disclosure will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 are a perspective view of a machine, such as a baler, having awrap assembly in accordance with one implementation of the presentdisclosure.

FIGS. 5a-5c illustrate various wrap paths of the wrap assembly.

FIGS. 6a-6d illustrate a first implementation of the wrap assembly invarious positions of the wrapping process.

FIGS. 7a-7d illustrate a second implementation of the wrap assembly invarious positions of the wrapping process.

FIGS. 8a-8d illustrate a third implementation of the wrap assembly invarious positions of the wrapping process.

FIG. 9 illustrates various tension profiles.

DETAILED DESCRIPTION

Before any implementations of the disclosure are explained in detail, itis to be understood that the disclosure is not limited in itsapplication to the details of the formation and arrangement ofcomponents set forth in the following description or illustrated in theaccompanying drawings. The disclosure is capable of supporting otherimplementations and of being practiced or of being carried out invarious ways.

The disclosure relates to a bale wrapping mechanism and moreparticularly to a bale wrapping mechanism able to apply wrappingmaterial to a finished bale under tension to maintain the density levelof the bale material. In particular, forming bales at particularly highdensity levels (i.e., upwards of 30 lb/ft³) changes the underlying cropmaterial's rheological properties causing the stems of the crop materialto become smashed and crushed to the point where the crop material hasvirtually no tubular structure and loses its ability to support a load.As such, the highly compressed crop material cannot rebound or expandafter it has been compressed. Due to these properties, highly compressedbales must be constantly maintained in a compressed state to maintainthe bale's integrity, shape, and density. The illustrated bale wrappingmechanism applies the wrap material under tension to the finished baleto maximize the bale's integrity and density. Still further, the netwrapping mechanism is configured so that the mechanism can accommodatebales of different sizes and shapes.

Referring to FIGS. 1-4, a baler 10 includes a frame 14, a set of wheels18 mounted on the frame 14, a feed system 22 coupled to the frame 14, acompression system 26 to receive and compress crop material provided bythe feed system 22, a wrap assembly 38 to wrap the finished bale 42 inwrap material 46, and a controller (not shown) to monitor and direct thebaling operation. In the illustrated implementation, the baler 10 is asquare baler for creating finished bales 42 of a crop, such as hay,straw, or other biomasses.

In the illustrated implementation, the frame 14 of the baler 10 includesa tow bar (not shown) extending from the frame 14 and connectable to atowing vehicle (not shown), such as an agricultural tractor or otherdriven vehicle. The baler 10 also includes a power takeoff shaft (notshown) connectable to the towing vehicle to transmit a rotating driveforce from the towing vehicle to various components of the baler 10. Inother implementations, the baler 10 may have a dedicated power supplyand/or prime mover (not shown), such as an engine, motor, battery, fuelcell, etc., for driving the wheels 18 and for driving and/or poweringthe various components of the baler 10.

As shown in FIGS. 1-4, the feed system 22 is configured to pick upwindrowed crop material 34 from a support surface 58 (e.g., from afield) and convey the crop material 34 to the compression system 26 forsubsequent processing. In the illustrated implementation, the feedsystem 22 includes a pickup assembly 62 for collecting the crop material34 from the support surface 58, a pre-cutter 66 to re-size the cropmaterial 34 into smaller, more manageable pieces, and an acceleratorroll 70 to direct the crop material 34 into the compression system 26.

The compression system 26 of the baler 10 includes an auger stylecompression system 26 utilizing one or more augers 74 which rotate withrespect to the frame 14 to compress the crop material 34 received fromthe feed system 22. During baling operations, the augers 74 rotateproducing a continuous output of highly compressed bale material in theform of an extrusion 82.

Illustrated in FIGS. 1-4, the wrap mechanism 38 of the baler 10 includesa frame 94 defining a volume 98 therein, a resistance assembly 102 inoperable communication with the volume 98, an ejection assembly 106 inoperable communication with the volume 98, a cutting assembly 110positioned opposite the resistance assembly 102, a wrap chute 114positioned opposite the ejection assembly 106, and a wrap assembly 118coupled to the frame 94 proximate the wrap chute 114. During use, thewrap mechanism 38 is configured to receive and process the extrusion 82of compressed bale material from the compression system 26 to create afinished bale shape 42, re-position the finished bale shape 42 withinthe wrap chute 114 for wrapping, apply wrapping material 46 to theoutside of the bale 42, and eject the wrapped bale 42 for subsequentpickup.

Illustrated in FIGS. 1-4, the frame 94 of the wrap mechanism 38 issubstantially rectangular in shape and includes a top wall 122, and abottom wall 126 spaced a distance from the top wall 122 to at leastpartially define the volume 98 therebetween. Together, the top wall 122and the bottom wall 126 also define a first side or inlet 130 throughwhich the extrusion 82 enters the volume 98. The top wall 122 and bottomwall 126 also define a second end 134 opposite the inlet 130, a thirdend 138 extending between the first side 130 and the second side 134,and a fourth end 142 opposite the third side 138. The frame 94 alsodefines a first axis 146 extending through the volume 98 between thefirst and second sides 130, 134, and a second axis 150 transverse orperpendicular to the first axis 146 that extends through the volume 98between the third and fourth sides 138, 142.

In the illustrated implementation, the distance between the top wall 122and the bottom wall 126 is substantially equal to or slightly smallerthan the desired height of the completed bale 42 so that the top andbottom walls 122, 126 may provide a compressive force on the top andbottom surfaces of the extrusion 82 and finished bale 42. While notillustrated, the distance between the top and bottom walls 122, 126 mayalso be adjustable to allow the wrap mechanism 38 to adjust thecompressive forces applied to the extrusion 82 and finished bale 42.Furthermore, the distance between the top and bottom walls 122, 126 maybe adjusted to accommodate bales 42 of different sizes and shapes (e.g.,different heights). Still further, the distance between the top andbottom walls 122, 126 may also be used to vary the resistance applied ofthe extruded bale material 82 to resist the motion of the extrusion 82toward the second end 134 of the volume 98.

While not illustrated, the frame 94 may also include rollers, rails,shuttles, and the like to aid the movement of the extrusion 82 andfinished bale 42 within the volume 98.

Illustrated in FIGS. 1-4, the resistance assembly 102 of the wrapmechanism 38 includes an actuator 154 coupled to the frame 94 oppositethe inlet 130 (e.g., proximate the second end 133), and a resistanceplate 158 coupled to the actuator 154 and movable with respect thereto.The resistance plate 158 is at least partially positioned within thevolume 98 of the frame 94 and is movable with respect thereto along thefirst axis 146 between a first position (see FIG. 1), where theresistance plate 158 is positioned proximate the inlet 130, and a secondposition (see FIG. 3), where the resistance plate 158 is positioned awayfrom the inlet 130 (e.g., proximate the second end 133 of the volume98).

During the baling process, the resistance plate 158 is configured tocontact the leading surface 160 of the extrusion 82 and resist theextrusion's movement toward the second end 133. More specifically, theresistance plate 158 is initially positioned proximate the inlet 130(i.e., in the first position) and in contact with the leading surface160 of the extrusion 82. Therefore, as the leading surface 160 of theextrusion 82 moves toward the second end 134 of the volume 98 (e.g., asthe extrusion 82 grows due to continued baling operations), theresistance plate 158 begins to move toward the second position. Inresponse, the actuator 154 resists the motion of the resistance plate158 producing a resistance force that is applied to the leading surface160 of the extrusion 82 compressing the protrusion. Depending on thedesired characteristics of the finished bale 42, the level of resistanceprovided by the actuator 154 may be varied to at least partiallydetermine the resulting density of the bale 42. For example, higherresistance levels will result in higher density bales 42, while lowerresistance levels will result in lower density bales 42.

Illustrated in FIGS. 1-4, the cutting assembly 110 of the wrap mechanism38 includes an actuator 202 coupled to the frame 94 proximate the inlet130, and a cutting plate 206 coupled to the actuator 202 and movablewith respect thereto. More specifically, the cutting plate 206 isactively driven by the actuator 202 with respect to the frame 94 in adirection transverse or substantially perpendicular the first axis 146(e.g., across the inlet 130) between a retracted position (see FIG. 1),where the cutting plate 206 is positioned outside the volume 98, and anactuated position (see FIG. 3), where the cutting plate 206 is at leastpartially positioned within the volume 98 and the volume 98 is isolatedfrom the compression system 26. In the illustrated construction, thecutting plate 206 of the cutting assembly 110 includes a sharpenedleading edge 208 able to pass through and cut the extrusion of cropmaterial 82 when moving from the retracted to actuated positions.

During use, the cutting assembly 110 of the wrap mechanism 38 isconfigured to cut off a portion of the extrusion 82 to form the finishedbale 42. More specifically, once a desired length of the extrusion 82 ispositioned within the volume 98 of the wrap mechanism 38 (i.e., thelength of the extrusion 82 positioned within the volume 98 is equal tothe desired length of the final bale 42), the actuator 202 of thecutting assembly 110 biases the cutting plate 206 toward the actuatedposition. As the cutting plate 206 moves from the retracted position tothe actuated position, the leading edge 208 of the cutting plate 206cuts through the extrusion 82 isolating the portion of the extrusion 82positioned within the volume 98 from the remainder of the extrusion 82thereby creating the final bale 42. Once the cutting plate 206 is in theactuated position, the cutting plate 206 acts as a resistance membermaintaining resistive forces against the newly formed leading surface160 of the extrusion 82.

Illustrated in FIGS. 1-4, the ejection assembly 106 of the wrapmechanism 38 includes an actuator 178 coupled to the frame 94 proximatethe third side 138, and an ejection plate 182 coupled to the actuator178 and movable with respect thereto. The ejection plate 182 is at leastpartially positioned within the volume 98 of the frame 94 and is movablewith respect to the frame 94 along the second axis 150 between a firstposition (see FIG. 1), where the ejection plate 182 is positionedproximate the third side 138 of the volume 98, and a second position(see FIG. 4), where the ejection plate 182 is positioned proximate thefourth side 142 of the volume 98.

During use, the ejection assembly 106 is configured to bias the finishedbale 42 positioned within the volume 98 along the second axis 150 andinto the wrap chute 114. More specifically, after the finished bale 42has been isolated from the compression system 26 by the cutting plate206, moving the ejection plate 182 from the first position toward thesecond position causes the completed bale 42 to move into the passageway226 of the wrap chute 114 for subsequent wrapping (described below).

Illustrated in FIGS. 1-4, the wrap chute 114 of the wrap mechanism 38includes a base wall 218 at least partially forming the third side 138of the volume 98, and a perimeter wall 222 extending outwardly from thebase wall 218 to define a passageway 226 in communication with thevolume 98 therein. During use, the wrap chute 114 is configured to atleast partially receive the final bale 42 within the passageway 226 suchthat the perimeter wall 222 contacts and maintains the bale 42 undercompression. Once the bale 42 is positioned within the wrap chute 114,wrapping material 230 may be wrapped around the exterior surface 234 ofthe perimeter wall 222 thereby encompassing the bale 42 containedtherein (e.g., with the perimeter wall 222 positioned between the bale42 and the wrap material 46).

The passageway 226 of the wrap chute 114 is substantially rectangular incross-sectional shape and includes a chute axis 238 extendinglongitudinally therethrough. More specifically, the illustratedpassageway 226 defines a cross-sectional size and shape substantiallycorresponding with the height and length of the finished bale 42. In theillustrated implementation, the passageway 226 is substantially constantin cross-sectional shape along its entire axial length, however, inother implementations the cross-sectional shape and size of thepassageway 226 may vary along its axial length. For example, thepassageway 226 may reduce in cross-sectional size (i.e., neck inward) asit extends away from the base wall 218 to help compress the sides of thebale 42 as it enters the chute 114.

The perimeter wall 222 of the wrap chute 114 extends outwardly from thebase wall 218 and along at least a portion of the perimeter of thepassageway 226. More specifically, the perimeter wall 222 extends fromthe base wall 218 a distance substantially corresponding to the width ofthe finished bale 42 so that the entire finished bale 42 may bepositioned within the passageway 226 at any one time. In the illustratedimplementation, the perimeter wall 222 includes four substantiallyplanar portions 242 a, 242 b, 242 c, 242 d connected by four roundedcorner portions 246. Together, the portions 242 and corners 246 producea substantially continuous perimeter wall 222 extending along the entireperiphery of the passageway 226. In alternative implementations, theperimeter wall 222 may be formed from multiple, individual walls (notshown) extending along portions of the perimeter of the passageway 226.In still other implementations, the size, location, and orientation ofthe perimeter wall 222 may be adjustable to accommodate finished bales42 of different sizes and shapes.

In the illustrated implementation, the perimeter wall 222 defines aplurality of apertures or notches 250 open to the passageway 226 andconfigured to permit the wrap material 46 wrapped around the exteriorsurface 234 of the perimeter wall 222 to contact the bale 42 positionedin the passageway 226. More specifically, each corner portion 246 of thewrap chute 114 includes a notch 250 exposing the corners of a bale 42positioned within the passageway 226 and permitting the wrap material 46to directly engage the corner edge of the finished bale 42. The directengagement between the wrap material 46 and the bale 42 allows the twoelements to move together as a unit when the bale 42 is moved withrespect to the perimeter wall 222 within the wrap chute 114.Furthermore, the interaction between the bale 42 and the wrap material46 is such that the wrap material 46 effectively becomes coupled to thebale 42 in the areas where the two are in direct engagement with oneanother. In contrast, the wrap material 46 tends to slide relative tothe perimeter wall 222. Thus, the wrap material 46 will not fall off thebale 42 when being ejected from the wrap chute 114.

While the illustrated notches 250 are formed into a respective cornerportion 246 of the perimeter wall 222, in alternative implementation,more or fewer notches 250 may be present or positioned in alternativepositions on the perimeter wall 222 such as the planar portions 242 andthe like.

Illustrated in FIGS. 6a -6 d, the wrap assembly 118 of the wrapmechanism 38 includes a wrap arm 258 mounted to the frame 94 and havinga mounting point 262 movable with respect to the wrap chute 114, a shaft266 coupled to the mounting point 262 of the wrap arm 258, a roll 272 ofwrap material 46 rotatably mounted to the shaft 266, and a brakeassembly 276 operatively coupled to the shaft 266 and configured to atleast partially limit the rotation of the roll 272. During use, the wraparm 258 is configured to direct the shaft 266 (and the roll 272 attachedthereto) along a wrap path 280 (see FIGS. 5a-5c ) to apply the wrapmaterial 46 to the exterior of a bale 42 positioned within thepassageway 226 of the wrap chute 114. In some implementations, the wraparm 258 is configured such that the wrap path 280 may be adjusted toaccommodate bales 42 of different sizes, shapes, and densities.

Illustrated in FIGS. 5a -5 c, the wrap path 280 of the wrap assembly 118partially or completely encircles the perimeter wall 222 and isgenerally non-circular in shape. More specifically, the wrap path 280 isgenerally shaped to correspond with the cross-sectional shape of thepassageway 226. In some implementations, the wrap path 280 may include asubstantially rectangular shape including any shape having two sets ofparallel sides. In other implementations, the wrap path 280 may includea scaled contour of the cross-sectional shape of the passageway 226. Forexample, if the cross-sectional shape of the passageway 226 includes arectangle sized 2 units high H₁ by 4 units wide W₁, the wrap path 280may include a scaled contour that includes a rectangle that is 3 unitshigh H₂ by 6 units wide W₂ (e.g., scaled up by 1.5×; see FIG. 5b ). Inother implementations, the wrap path 280 may be configured such that thewrap path 280 maintains substantially a constant distance from theperimeter wall 222 for at least one complete rotation about thepassageway 226 (see FIG. 5a ).

In still other implementations, the wrap path 280 may only maintain asubstantially constant distance from each planar portion 242 a, 242 b,242 c, 242 d of the perimeter wall 222 (see FIG. 5c ). In still otherimplementations, the wrap path 280 may include a plurality of pathportions 281 a, 281 b, 281 c, 281 d each extending parallel to acorresponding one of the substantially planar wall portions 242 a, 242b, 242 c, 242 d, of the perimeter wall 222 (see FIG. 5c ). In suchimplementations, each path portion 281 a, 281 b, 281 c, 281 d of thewrap path 280 may be substantially parallel a corresponding wall portion242 a, 242 b, 242 c, 242 d but extend a distance greater than thecorresponding wall portion 242 a, 242 b, 242 c, 242 d (see FIG. 5c ).

In still other implementations, the shape of the wrap path 280 may bedictated by the resulting tension in the wrap material 46. In suchimplementations, the wrap path 280 may be shaped such that the wrapmaterial 46 is unwound from the roll 272 at a substantially constanttension for at least one complete rotation about the passageway 222.

In still other implementations, the wrap path 280 may be subdivided intoone or more segments (not shown) each of which are separated by a notch250 formed into the perimeter wall 222. For example, applying wrapmaterial 46 to the perimeter wall 222 between a first notch 250 a and asecond notch 250 b (e.g., along the first planar wall portion 242 a)constitutes a first segment of the wrap path 280, while applying wrapmaterial 46 between the second notch 250 b and a third notch 250 c(e.g., along the second planar wall portion 242 b) constitutes a secondsegment of the wrap path 280, while applying wrap material 46 betweenthe third notch 250 c and a fourth notch 250 d (e.g., along the thirdplanar portion 242 c) constitutes a third segment of the wrap path 280,and applying wrap material between the fourth notch 250 d and the firstnotch 250 a (e.g., along the fourth planar portion 242 d) constitutes afourth segment of the wrap path 280 (see FIG. 6A). In suchimplementations, each segment is separated by a notch 250 which allowsthe wrap material 46 to directly engage the bale 42 and “lock in” thetension in the wrap material 46 over the previous segment. Thus, themagnitude of the tension applied to each segment can be adjustedindependently.

Illustrated in FIGS. 6a -6 d, the roll 272 of wrap material 254 isconfigured to be positioned on the spindle 316 of the shaft 266 androtate therewith (described below). The roll 272 also includes a lengthof wrap material 46 wound about the roll 272. The wrap material 254 mayinclude any type of wrap material as is known in the bale wrapping artsuch as, but not limited to, traditional net wrap, solid plastic wrap,plastic wrap with apertures, and breathable wrap. During use, the wrapmaterial 46 is unwound from the roll 272 during the wrapping process.

Illustrated in FIGS. 6a -6 d, the wrap arm 258 of the wrap assembly 118includes a support 274 fixedly coupled to the base wall 218, a firstmember or first wrapping arm 278 pivotably coupled to support 274, and asecond member or second wrapping arm 282 pivotably coupled to the firstmember 278 and including the mounting point 262. During use, the firstmember 278 pivots with respect to the support 274 and the second member282 pivots with respect to the first member 278 to dictate the relativelocation of the mounting point 262 with respect to the wrap chute 114(e.g., along the wrap path 280).

The first member 278 of the wrap arm 258 is substantially elongated inshape having a first end 286 pivotably coupled to the support 274, and asecond end 290 opposite the first end 286. The first member 278 alsoincludes a first actuator 292 positioned proximate the first end 286 andin operable communication with the support 274. During use, the firstactuator 294 is configured to generate torque causing the first member278 to pivot with respect to the support 274 about a first axis 296. Inthe illustrated implementation, the first actuator 294 includes a servomotor, however in alternative implementations, hydraulic actuators,linear actuators, and the like may be used.

The second member 282 of the wrap arm 258 is substantially elongated inshape having a first end 300 pivotably coupled to the second end 290 ofthe first member 278, and the mounting point 262 positioned opposite thefirst end 300. The second member 282 also includes a second actuator 304positioned proximate the first end 300 and in operable communicationwith the first member 278. During use, the second actuator 304 isconfigured to generate torque causing the second member 282 to pivotwith respect to the first member 278 about a second axis 308. In theillustrated implementation, the second actuator 304 includes a servomotor, however in alternative implementations, hydraulic actuators,linear actuators, and the like may be used.

In the illustrated construction, both the first axis 296 and the secondaxis 308 are substantially parallel to the chute axis 238 of the wrapchute 114. As such, the mounting point 262 may be moved with two degreesof freedom within a plane that is oriented normal to the chute axis 238.In alternative implementations, more of fewer members and actuators maybe utilized (not shown) to provide additional degrees of freedom asnecessary to produce the desired motion of the mounting point 262.

Illustrated in FIGS. 6a -6 d, the shaft 266 of the wrap assembly 118 iscoupled to the mounting point 262 of the wrap arm 258 a and configuredto rotatably support the roll 272 of wrap material 46 thereon. Morespecifically, the shaft 266 includes a base 312 fixedly coupled to themounting point 262 of the wrap arm 258, and a spindle 316 mounted to thebase 312 for rotation about a shaft axis 320. In the illustratedconstruction, the shaft axis 320 is substantially parallel to the chuteaxis 238 so that the wrap material 46 is able to lay flat against theouter surface 160 of the perimeter wall 222.

The spindle 316 of the shaft 266 is substantially elongated in shape andconfigured to be detachably coupled to the roll 272 of wrap material 46.More specifically, the spindle 316 may include one or more protrusions,keyways, splines, and the like (not shown) configured to engage withcorresponding geometry of the roll 272 so that when a roll 272 ispositioned on the spindle 316, the roll 272 and spindle 316 rotatetogether as a unit. Furthermore, the spindle 316 may include some formof locking assembly (not shown) to secure the roll 272 on the spindle316 during operation.

Illustrated in FIGS. 6a -6 d, the brake assembly 276 of the wrapassembly 118 includes a brake disk 324 fixedly coupled to one of thespindle 316 and the base 312 of the shaft 266, and a caliper 328selectively engaging the brake disk 324 and fixedly coupled to the otherof the spindle 316 and the base 312 of the shaft 266. During use, thebrake assembly 276 is configured to selectively resist the relativerotation of the spindle 316 (and the roll 272 positioned thereon) withrespect to the base 312 about the shaft axis 320. By doing so, the brakeassembly 276 is able to at least partially dictate the tension containedwithin the wrap material 46 being applied to the bale 42 (e.g., atension profile) independent of the current diameter of the roll 272.While the brake assembly 276 of the illustrated implementation includesa disk brake system, it is to be understood that any system able toselectively restrict the rotation of the spindle 316 may be used, suchas a drum brake, a hydraulic motor, an electric motor, and the like.

The unroll tension profile of the wrap assembly 118 includes the levelof tension imparted on the wrap material 46 as it is being unrolled fromthe roll 272 as the shaft 320 travels around the corresponding wrap path280. In some implementations, the unroll tension profile may includemaintaining a substantially constant level of tension in the wrapmaterial 46 for at least one complete circuit about the passageway 226.In still other implementations, the unroll tension profile may vary fromwrap material layer to wrap material layer. For example, the unrolltension profile may include a first tension level for the first layer ofwrap material 46, and a second tension level for the second layer ofwrap material 46 different from the first tension level. In still otherimplementations, the unroll tension profile may vary over the distanceof the wrap path 280.

In other implementations, the applied tension profile includes the levelof tension in the wrap material 46 after it has been applied to the bale42. In some implementation, the applied tension profile may includehaving a constant level of tension 241 for a complete circuit about thepassageway 226 or wrap path 280 (see FIG. 9). In other implementations,the applied tension profile may include having the tension level varyover the length of the wrap path 280. For example, the wrap material 46may be applied at a first tension level 243 across the first planar wallportion 242 a, a second tension level 245 different from the firsttension level across the second planar wall portion 242 b, and so on(see FIG. 9). In still other implementations, the tension profile mayvary from wrap material layer to wrap material layer. For example, thetension profile may include a first tension level for the first layer ofwrap material 46, and a second tension level for the second layer ofwrap material 46 different from the first tension level.

In still other implementations, the tension level of the wrap material46 may vary for each segments of the wrap path (described above). Insuch implementations, the profile map illustrates a substantiallyinstantaneous change in tension levels between different segments. Thischange in tension is possible due to the fact that the various segmentsare separated by a notch 250. As such, the wrap material 46 engages andbecomes substantially fixed relative to the bale 46 at the notches 250(e.g., the exposed corner regions of the bale 46; described above). Assuch, the brake assembly 276 and wrap arm 258 are able to apply andadjust the tension of each segment of the wrap path 280 independently ofone another.

During the baling operation, the wrap mechanism 38 receives a steadyflow of compressed crop material from of the compression system 26 inthe form of a continuously growing extrusion 82. More specifically, thelead surface 160 of the extrusion 82 moves through the inlet 130, intothe volume 98, and toward the second end 134. As described above, theresistance plate 158 of the resistance assembly 102 contacts the leadsurface 160 of the extrusion 82 providing a resisting force against themovement of the extrusion 82 toward the second end 134 therebymaintaining the extrusion 82 under compression. As the extrusion 82continues to grow during the baling operation, the resistance plate 158moves from the first position (FIG. 1) toward the second position (FIG.3).

Once the extrusion 82 has expanded such that the length of thecompressed extrusion material positioned beyond the inlet 130substantially corresponds with the desired final bale length (e.g., theresistance plate 158 is in the second position; see FIG. 3), the cuttingassembly 110 begins the cutting procedure.

During the cutting procedure, the cutting plate 206 moves from theretracted position (FIG. 1) toward the deployed position (FIG. 3)causing the leading edge 208 of the cutting plate 206 to cut theextrusion 82 thereby forming the a first bale 42 a within the volume 98and creating a new lead surface 160 b for the extrusion 82. The cuttingplate 206 also covers the inlet 130 of the volume 98 so that the newlead surface 160 cannot enter the volume 98.

With the first bale 42 a formed, the ejection assembly 106 begins theejection procedure. During the ejection procedure the ejection plate 138moves from the first position (FIG. 3) toward the second position (FIG.4). By doing so, the ejection plate 182 biases the first bale 42 a outof the volume 98 and into the passageway 226 of the wrap chute 114. Theejection plate 182 continues to bias the bale 42 a until the entire bale42 a is positioned within the passageway 226.

With the bale 42 positioned within the passageway 226, the wrappingprocedure begins. During the wrapping procedure, the wrapping arm 258begins moving the shaft 266 along the first segment of the desired wrappath 280 (described above) causing a length of wrapping material 46 tounroll from the roll 272 and be applied to the exterior surface 234 ofthe perimeter wall 222 and the first bale 42 (e.g., via contact throughthe notches 250 formed in the wall 222). Furthermore, the brake assembly276 selectively resists the rotation of the roll 272 with respect to thebase 312 creating tension within the applied wrap material 46.

As the wrapping arm 258 travels along the first segment and toward thefirst notch 250 a, the brake assembly 276 adjusts the tension within thewrap material 46. More specifically, the brake assembly 276 isconfigured to generate the desired tension at the moment when the wrapmaterial 46 is applied to the first notch 250 a of the wall 222. Bydoing so, the brake assembly 276 assures the tension is at the propervalue when the wrap material 46 engages the bale 42 and “locks in” thetension over the first segment (described above). The wrapping arm 258then travels along the second segment of the wrap path 280 and towardthe second notch 250 b. Again, the brake assembly 276 is configured toassure that the tension in the wrap material 46 is at the proper levelwhen the wrap material 46 is applied to the second notch 250 b and thetension for the second segment is “locked in.” To note, the engagementof the wrap material 46 with the bale 42 at the corresponding notches250 allows the tension over each segment to be different withouteffecting the tension of the previous segment. The wrapping arm 258 andbrake assembly 276 then continue this process for each subsequentsegment until a complete cycle of the wrap path 280 is complete.

The wrapping arm 258 continues to direct the shaft 266 along the wraproute 280 until the desired number of revolutions (e.g., layers of wrapmaterial 46) has been applied. Once complete, a cutter 288 (see FIG. 6a) as is well known in the art severs the applied wrap material 46 fromthe roll 272.

While the current implementation utilizes the same wrap route 280 andtension profile for each revolution about the passageway 226, it is tobe understood that in alternative implementations each revolution aboutthe passageway 226 may include a unique wrap route 280 and/or tensionprofile.

Concurrent with the wrapping procedure, a reset procedure also begins.During the reset procedure the ejection plate 182 returns to the firstposition (FIG. 1) proximate the third end 138 of the frame 94 and theresistance plate 158 returns to the first position (FIG. 1).Furthermore, the cutting plate 206 returns to the retracted position(FIG. 1) allowing the new lead surface 160 b of the extrusion 82 tocontact the resistance plate 158. Once the new lead surface 160 bcontacts the resistance plate 158, the extrusion 82 begins biasing theresistance plate 158 toward the second position, as described above,until sufficient extrusion material has entered the volume 82 for thecutting procedure to begin, as described above, to create a second bale42 b (see FIG. 3).

Once the wrapping procedure and cutting procedure are both completed,the ejection plate 182 begins the ejection procedure. In this instance,however, in addition to moving the second bale 42 b into the wrap chute114 as describe above, the first bale 42 a is biased by the second bale42 a causing the first bale 42 to be ejected from the wrap chute 114 forsubsequent collection (see FIG. 4). Once the second bale 42 b ispositioned within the wrap chute 114, the process can begin anew.

FIGS. 7a-7d illustrate a second implementation of a wrap arm 500. Thewrap arm 500 includes a first pair of rails 504 extending substantiallyparallel one another and fixed relative to the base wall 508, a firstshuttle 512 movable with respect to the first set of rails 504, and asecond shuttle 516 movable with respect to the first shuttle 512 andincluding the mounting point 262. In the illustrated construction, thefirst pair of rails 504 are substantially parallel to the base wall 508.

The first shuttle 512 of the wrap arm 500 includes a pair of end blocks520 and a second pair of rails 524 extending between the end blocks 520.When assembled, each end block 520 is slidably coupled to acorresponding one of the first pair of rails 504 for movement along thelength thereof. Furthermore, each rail of the second pair of rails 524is oriented transverse or substantially perpendicular to the first pairof rails 504. The first shuttle 512 also includes one or more actuators528 coupled to a corresponding one of the end blocks 520 and configuredto provide a force for driving the first shuttle 512 along the length ofthe first pair of rails 504. In the illustrated construction, eachactuator 528 includes a servo motor having a drive wheel 532 configuredto engage a corresponding one of the first set of rails 504. However inalternative implementations, actuator 528 may include a linear actuator,hydraulic actuator, and the like.

The second shuttle 516 of the wrap arm 500 includes a body 534 slidablycoupled to the second pair of rails 524 for movement along the lengththereof. The second shuttle 516 also includes the mounting point 262 towhich the shaft 266 may be coupled. The second shuttle 516 furtherincludes an actuator 536 coupled to the body 532 and configured toprovide a force for driving the second shuttle 516 along the length ofthe second pair of rails 524. In the illustrated construction, theactuator 536 includes a servo motor having a drive wheel 540 configuredto engage one of the second set of rails 524. However in alternativeimplementations, the actuator 536 may include a linear actuator,hydraulic actuator, and the like.

During use, movement of the first and second shuttles 512, 516 causesthe mounting point 262, and the corresponding shaft 266 to move withrespect to the bale chute 114 (e.g., along a wrap path 280).Furthermore, the orientation of the first and second pair of rails 504,524 allow the mounting point 262 to be moved with two degrees of freedomwithin a plan that is oriented normal to the chute axis 238. Inalternative implementations, more or fewer shuttles may be used toprovide additional degrees of freedom as necessary to produce thedesired motion of the mounting point 262.

FIGS. 8a-8d illustrate a third implementation of the wrap arm 600. Thewrap arm 600 includes a support 604 fixedly coupled to the base wall 218of the bale chute 114, a first member or first wrapping arm 608pivotably coupled to the support 604, and a slider 612 slidably coupledto the first member 608 and defining the mounting point 262.

The first member 608 of the wrap arm 600 is substantially elongated inshape having a first end 616 pivotably coupled to the support 604, and asecond end 620 opposite the first end 616. The first member 608 alsoincludes a first actuator 624 positioned proximate the first end 616 andin operable communication with the support 604. During use, the firstactuator 624 is configured to generate torque causing the first member608 to pivot with respect to the support 604 about a first axis 628. Inthe illustrated implementation, the first actuator 624 includes a servomotor, but in alternative implementations, hydraulic actuators, linearactuators, and the like may be used.

The slider 612 of the wrap arm 600 includes a body 632 slidably coupledto the first member 608 and movable along the length thereof between thefirst end 616 and the second end 620. The slider 612 also includes themounting point 262 and a second actuator 636 configured to provide aforce for driving the slider 612 along the length of the first member608. In the illustrated implementation, the actuator 636 includes aservo motor having a drive wheel 640 configured to engage the firstmember 608. However in alternative implementations, actuator 636 mayinclude a linear actuator, hydraulic actuator, and the like.

During use, the pivotal movement of the first member 608 with respect tothe support 604 and the translational motion of the slider 612 withrespect to the first member 608 allow the mounting point 262 to be movedwith two degrees of freedom within a plane that is orientedsubstantially normal to the chute axis 238. In alternativeimplementations, members or sliders may be used to provide additionaldegrees of freedom as necessary to produce the desired motion of themounting point 262.

Various features of the disclosure are set forth in the followingclaims.

The invention claimed is:
 1. A bale wrap mechanism for wrapping a balewith wrap material, the bale wrap mechanism comprising: a frameincluding a wrap chute formed from one or more perimeter walls, whereinthe wrap chute includes a wrap axis extending longitudinallytherethrough, wherein the one or more perimeter walls at least partiallydefine a passageway through which the bale may be passed, wherein thepassageway has a rectangular cross-sectional shape taken perpendicularto the wrap axis and corresponding to a cross-sectional shape of thebale, and wherein the one or more perimeter walls form one or morenotches through which the wrap material may contact the bale; a wrap armhaving a mounting point movable with respect to the frame, the wrap armincluding: a first rail fixedly coupled to the frame; a first shuttlemovable along a length of the first rail, wherein the first shuttle ismovable along the first rail to adjust a position of the first shuttlein a first direction perpendicular to the wrap axis, wherein the firstshuttle includes a second rail that is transverse to the first rail; anda second shuttle movable along a length of the second rail, wherein thesecond shuttle is movable along the second rail to adjust a position ofthe second shuttle in a second direction perpendicular to the wrap axis,wherein the second shuttle includes the mounting point; a roll coupledto the mounting point of the wrap arm, the roll having at least aportion of the wrap material wrapped thereon; and a brake assemblyconfigured to adjust a tension of the wrap material, wherein themounting point is configured to travel along a wrap path during a wrapprocess, wherein the wrap path includes a plurality of segments eachseparated from one another by one of the one or more notches, whereinthe brake assembly is configured to adjust the tension of the wrapmaterial in each segment independently.
 2. The bale wrap mechanism ofclaim 1, wherein the wrap path completely surrounds the passageway. 3.The bale wrap mechanism of claim 2, wherein the wrap path is defined bya start point and an end point, wherein the start point and the endpoint are one and the same.
 4. The bale wrap mechanism of claim 1,wherein the wrap path is rectangular in shape.
 5. The bale wrapmechanism of claim 1, wherein the wrap path includes a scaled contour ofthe cross-sectional shape of the passageway oriented perpendicular tothe wrap axis.
 6. The bale wrap mechanism of claim 1, wherein the brakeassembly is configured to adjust the tension of the wrap materialindependent of a diameter of the roll.
 7. The bale wrap mechanism ofclaim 1, wherein at least one of the one or more notches is positionedat a corner of the wrap chute.
 8. The bale wrap mechanism of claim 1,wherein at least a portion of the one or more perimeter walls isparallel to the wrap axis.
 9. A bale wrap mechanism for use with a rollof wrap material, the bale wrap mechanism comprising: a frame includinga wrap chute formed from one or more perimeter walls, wherein the wrapchute includes a wrap axis extending longitudinally therethrough, andwherein the one or more perimeter walls at least partially define apassageway; a first rail fixedly coupled to the frame; a first shuttlemovable along a length of the first rail, wherein the first shuttle ismovable along the first rail to adjust a position of the first shuttlein a first direction perpendicular to the wrap axis, wherein the firstshuttle includes a second rail that is transverse to the first rail; asecond shuttle movable along a length of the second rail, wherein thesecond shuttle is movable along the second rail to adjust a position ofthe second shuttle in a second direction perpendicular to the wrap axis,wherein the second shuttle includes a mounting point; and a shaftcoupled to the mounting point, wherein the shaft is configured torotatably support the roll of wrap material thereon, wherein the shaftis configured to travel along a wrap path during a wrapping process,wherein the wrap path surrounds the passageway, and wherein the wrappath is non-circular in shape.
 10. The bale wrap mechanism of claim 9,wherein the wrap path completely encompasses the passageway.
 11. Thebale wrap mechanism of claim 9, including a first actuator configured tomove the first shuttle with respect to the first rail, and a secondactuator configured to move the second shuttle with respect to thesecond rail.
 12. The bale wrap mechanism of claim 9, wherein the wrappath is rectangular in shape.
 13. The bale wrap mechanism of claim 9,further comprising a brake assembly configured to adjust a rate at whicha length of the wrap material is dispensed from the roll of wrapmaterial.
 14. The bale wrap mechanism of claim 9, wherein the passagewayincludes a rectangular cross-sectional shape taken perpendicular thewrap axis.
 15. The bale wrap mechanism of claim 9, wherein the secondrail is perpendicular to the first rail.